Battery case

ABSTRACT

A battery case comprising a pair of case members joined together along a seam to form a housing. Each case member includes a pair of sidewalls adapted to define a base surface on which the case rests so as to permit a plurality of resting orientations of the battery case. The seam is positioned above the lowermost base surface of the casing to contain any leaked battery acid regardless of case orientation. Further, the battery case includes supports for supporting the lower surface of the battery above any leaked acid, as well as partitions that define a discrete cavity for each battery to isolate the battery from an adjacent battery that may be leaking. The battery case also includes an electrical connector mounted for two dimensional movement that facilitates completion of a blind and automatic connection of the battery case with a complementary connector.

FIELD OF THE INVENTION

[0001] This invention relates to battery cases, and in particular tocases for use in an uninterruptible power supply.

BACKGROUND OF THE INVENTION

[0002] Uninterruptible power supplies (UPS) serve as back-up powersupplies to critical electrical devices during outages of regular powersupplies. The UPS is generally computer controlled and monitors thepower supplied to the electrical device, switching on the back-up powersupply if the normal power supply becomes insufficient. Therefore it iscrucial that the UPS be reliable even after periods of minimalmaintenance. A UPS typically draws its backup power from a set oflead-acid batteries connected in series and housed in a battery case.The battery cases are housed in a UPS cart with a front door that opensand allows the battery case to be slid into the cart and connected.

[0003] Current battery cases consist of a top piece and a bottom piececonstructed of a nonconducting material, usually a heavy plastic. Thebottom piece is divided into compartments by short fins, eachcompartment containing two or more batteries which have been adheredtogether. The batteries are wired in series and connected to anelectrical connector mounted in an end panel of the bottom piece. Thetop piece is then secured to the bottom piece to form a generallyrectangular container whose seam runs along the center of the container.

[0004] Battery cases provide for improved safety and handling oflead-acid batteries. As can be appreciated, lead-acid batteries posehazards due to the possible leakage of acid contained within thebattery. For example, acid leaked from a battery can cause shortcircuits and result in damage to equipment and an increased risk offires. While conventional battery cases are able to contain leaked acidwithin the case when the case is positioned correctly on its bottompiece, the battery case during installation may be dropped or set downon a side having a seam through which the acid may leak. Conventionalcases also do not effectively protect other batteries within the casefrom the leaked acid. The presence of the seam also limits the case to asingle orientation within the UPS. Accordingly a different battery casehas generally been required for each different style of UPS.

[0005] Further, the UPS electrical connections are located at the backof elongated narrow bays defined in the UPS cart for receiving thebattery cases. The connection therefore has usually been made by handwith minimal space and poor lighting. Such a hand connection requiresthat the UPS be powered down to prevent injuries, thus defeating thepurpose of a continuous backup power supply.

[0006] In an effort to eliminate manual coupling of the connectors, theconnectors have been mounted on stiff springs for limited movement. Thesprings function to press the connector forward and thereby allow theconnector members a limited amount of back and forth shifting in aneffort to achieve coupling of the connectors when the battery cases areinserted. However, this type of adjustment has proven to be largelyineffective. To better align the connectors, the battery cases have beenformed with guide members on their bottom surfaces for mating receipt inguiding grooves formed in the bays of the UPS shelves. However,connection is still difficult because of the stiffness of the springsand the weight of the cases, which can sometimes be over 100 pounds.

SUMMARY OF THE INVENTION

[0007] Accordingly, it is an object of the present invention to providea battery case that contains acid leaks from lead acid batteries so asto eliminate short-circuits of the batteries and other acid relatedinjuries to the user or equipment.

[0008] Another object of the present invention is to contain leaks ofthe battery regardless of the orientation of the battery case ondifferent sidewalls to allow for a range of installation configurationsand worry-free handling.

[0009] Another object of the present invention is to reduce the risk ofelectrical shocks during installation of the battery case byfacilitating a blind electrical connection that obviates the need forhandling the actual connectors in a difficult to reach place with poorlighting conditions.

[0010] A still further object of the invention is to achieve an easyautomatic coupling of the connector when the battery case is insertedinto a bay of a UPS.

[0011] In one aspect of the invention, a battery case comprises a pairof case members joined together to form a housing. Each case memberincludes a pair of sidewalls that serve not only to contain thebatteries, but are also adapted to support the case. Each case memberfurther includes a pair of transverse end walls interconnecting thesidewalls to form an enclosure about the batteries. The case members arejoined along a seam which is above the sidewall forming the lowermostbase wall for the casing so as to contain acid leaks within the casing.

[0012] In another aspect of the invention, the battery case comprisessupports for supporting the battery above the interior surface of thelowermost base wall of the battery case, and partitions that define adiscrete cavity for each battery. The supports and partitions guardagainst acid leaked from one battery contacting and affecting anotheradjacent battery.

[0013] In accordance with another aspect of the invention, each batterycase includes a connector electrically connected to the batteriesenclosed therein and a mount for attaching the connector that allows atleast two-dimensional movement of the connector relative to the housing.The mount and connector further include a guide structure thatcooperates with a guide structure of a complementary connector tofacilitate electrical coupling of the connectors. The ability of themount to have a two-dimensional freedom of movement and the use of guidestructures enables an easy blind and automatic connection of the twoconnectors.

[0014] The above and other objects, features and advantages of thepresent invention will be readily apparent and fully understood from thefollowing detailed description of preferred embodiments, taken inconnection with the appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015]FIG. 1 is a perspective view of one-half of a symmetricaltwo-piece battery case in accordance with the present invention.

[0016]FIG. 2 is a perspective view of the one-half of a battery caseshown in FIG. 1 with an electrical connector plate and lead-acidbatteries installed.

[0017]FIG. 3 is a side perspective view of the case shown in FIG. 2.

[0018]FIG. 4 is an enlarged fragmentary perspective view of one end ofthe case (with one-half omitted) with the connector plate receivingguides during installation in a UPS.

[0019]FIG. 5 is a perspective view of the battery case with second-halfof the battery case being closed over the batteries mounted in the firsthalf.

[0020]FIG. 6 is a perspective view of an uninterruptible power supplycart with the front door of the cart open, revealing four installedbattery cases.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] A battery case 10 in accordance with the present inventioncontains a plurality of electrically connected batteries to easehandling, contain leaks and facilitate enhanced connection during use.In a preferred embodiment, battery case 10 includes case members 20 thatare interconnected to enclose and contain the batteries. Case members 20are preferably identical for greater efficiency in manufacturing andgreater ease of assembly; although differences could be incorporated inthe case members if desired.

[0022] Each case member 20 includes a pair of sidewalls 26, 28interconnected along one edge to define a generally v-shaped grooveconfiguration. The sidewalls are joined at an angle of 90 degrees so asto form a generally rectangular container when the case members 20 arecoupled together. Sidewall 28 is typically longer to accommodate thelengths of the batteries which are usually greater than their heights.Of course, the dimensions of the case members could vary depending onthe size, shape and orientation of the batteries within the case. A pairof end walls 22, 24 interconnect sidewalls 26, 28 to form one-half ofthe enclosure. Sidewalls 26, 28 and end walls 22, 24 collectively definea case opening into which batteries 46 are placed during assembly.

[0023] The interior of each sidewall 26, 28 is provided with supports 32and partitions 33. In the preferred construction, a first set ofsupports 32 a, in the form of ridges, extend generally parallel to theouter edges 35, 36 of sidewalls 26, 28 to support an end of eachbattery. A second set of supports 32 b, in the form of discrete blocks,are provided along the connection of sidewalls 26, 28 to support theother end of each battery. In this way, the batteries are spaced fromthe interior faces 37, 38 of the sidewalls 26, 28 so that any leakage ofacid from the batteries flows onto the faces 37,38 without contacting oraffecting the other batteries.

[0024] More specifically, the battery case can be set so that eithersidewall 26 or 28 defines the lowermost base wall for supporting thebattery case. The provision of supports 32 on each face 37,38 thusproduce the same isolation effect from leaked battery acid. Of course,the supports 32 could be provided on only one face if the case were tobe set in only one orientation. Moreover, the supports may have anyshape or construction so long as the batteries are spaced from theinterior faces of the sidewalls.

[0025] Batteries 46 are further isolated from each other by partitions33. Partitions 33 are preferably formed as flanges upstanding from eachface 37, 38 to define a discrete cavity 39 for each battery. In thisway, a gap can be maintained between batteries so that leakage of acidfrom one battery does not contact an adjacent battery and cause ashort-circuit or other damage. Partitions 33 may have varying heights,widths, lengths, and shapes so long as they isolate the batteries fromeach other.

[0026] A joining face 40, 41 is defined along the outer edge of each ofthe sidewalls 26, 28 for facilitating connection with the complementarycase members. The joining faces 40, 41 are spaced from interior faces37, 38 by joining walls 42, 43. In this way, the end walls 22, 24, face37 or 38 and joining walls 42, 43 form a basin which collects andcontains any acid which may leak from one or more of the batteries andprevent seepage of the acid through the seam when the two case members20 are joined together. More specifically, if the case is supported onsidewall 26, the joining face 40 is spaced above face 37 by joining wall42 and adjoining face 41 is spaced above face 37 by sidewall 28 andjoining wall 43. Alternatively, if case 10 is supported on sidewall 28,the joining face 41 is spaced above face 38 by joining wall 43, andjoining face 40 is spaced above face 38 by sidewall 26 and joining wall42. Accordingly the seam is above the defined basin irrespective ofwhich sidewall 26, 28 forms the lowermost base wall for the batterycase. For additional assurance against acid leaking from the case, thejoining faces are preferably provided with a mating tongue 45 and groove43. Screws 44 are then received through holes 47 to secure the casemembers together. Nevertheless, case members 20 may be connected byother means such as sonic welding, riveting, gluing, etc.

[0027] An electrical connector assembly 50 for the battery case, as bestillustrated in FIG. 4, is secured in end wall 24 of the housing.Connector assembly 50 preferably comprises an off-the-shelf electricalconnector 52, known for UPS use, which is attached to a connector plate54 to extend through a connector hole 56. The connector plate 54 isloosely supported in a peripheral groove 57 for free motion in twodimensions (i.e., an x-y type motion). One half of the groove 57 isformed in the end plate 24 of each case member 20. Connector plate 54further has circular guide apertures 58 to receive guide pins 60 toshift and align the electrical connector 52 with the UPS matingconnector 62 as necessary. As seen in FIG. 4, the free ends 59 of guidepins 60 are tapered for guiding receipt into apertures 58. Other formsof complementary guides could also be used. The free movement ofconnector assembly 50 in end walls 24 enables the connector 52 toautomatically connect with the connector 62 of the UPS cart. Thisautomatic connection also allows for the battery cases to be“hot-swapped” (i.e., replaced) without shutting down UPS power.

[0028] The above described battery case 10 is especially suited for usein a UPS 64; although other uses are possible. UPS 64 typically has afront door 70 that opens to reveal bays 66 for insertion of the batterycases. Shelves 68 are provided in each bay to support the battery casesinserted therein. A completed battery case is lifted and slid end wall24 first into bay 66 along shelf 68 until guide pins 60 engage guideapertures 58 and connector 52 is electrically coupled to connector 62.

[0029] The above discussion concerns the preferred embodiments of thepresent invention. Various other embodiments as well as many changes andalternatives may be made without departing from the spirit and broaderaspects of the invention defined in the claims.

1. A battery case comprising a pair of case members which are joinedtogether to form a housing for at least one battery, each said casemember including a pair of non-parallel sidewalls, each said sidewallbeing adapted to define a lowermost base wall of the battery case forsupporting the battery case, a pair of transverse end wallsinterconnecting the sidewalls, and a pair of joining faces for abuttingthe joining faces of the other case member, each said joining face beingabove said lowermost base wall.
 2. A battery case in accordance withclaim 1 in which said sidewalls in each case member are joined togetherin a generally V-shaped configuration to define a generally rectangularhousing when assembled together.
 3. A battery case in accordance withclaim 2 in which longitudinal portions of said joining faces extendgenerally along outer edges of said sidewalls so as to be locatedgenerally at opposite comers of the rectangular housing.
 4. A batterycase in accordance with claim 1 in which said joining faces extendgenerally along an oblique plane relative to said sidewalls.
 5. Abattery case in accordance with claim 1 which further includes supportswithin the housing to support each battery at a position spaced frominterior faces of said sidewalls.
 6. A battery case in accordance withclaim 5 which further includes at least one partition to define aplurality of discrete cavities each adapted to receive a single batteryso that each battery is spaced from every other battery within thehousing.
 7. A battery case in accordance with claim 1 which furtherincludes at least one partition to define a plurality of discretecavities each adapted to receive a single battery so that each batteryis spaced from every other battery within the housing.
 8. A battery casein accordance with claim 1 which further includes a connectorelectrically connected to said batteries, and a mount which attachessaid connector to said housing for at least two dimensional movement ofsaid connector relative to said housing, one of said mount and connectorfurther including a guide structure to cooperate with a guide structureof a complementary connector to ease electrical coupling of theconnector with the complementary connector.
 9. A battery case inaccordance with claim 1 in which the case members are identical to oneanother.
 10. A battery case comprising a pair of case members which arejoined together along a seam to form a housing for at least one battery,each said case member including a pair of sidewalls and a pair of endwalls, said seam in said end walls being generally oblique relative tosaid sidewalls.
 11. A battery case in accordance with claim 10 in whichlongitudinal portions of said seam extend generally along outer edges ofsaid sidewalls so as to be located generally at opposite corners of arectangular housing.
 12. A battery case comprising a housing forenclosing a plurality of batteries, said housing including at least onelowermost base surface for supporting the battery case, supports withinsaid housing for supporting said batteries above the base surface, andat least one partition to define a discrete cavity for each battery sothat each battery is spaced from every other battery with said housing.13. A battery case in accordance with claim 12 in which each saidsidewall includes said supports.
 14. A battery case in accordance withclaim 13 in which each said sidewall includes said partitions.
 15. Abattery case in accordance with claim 14 in which said case members areidentical to one another.
 16. A battery case comprising a housing forcontaining a plurality of batteries, a connector electrically connectedto said batteries, and a mount attaching said connector to said housingfor at least two dimensional movement of said connector relative to saidhousing, one of said mount and connector further including a guidestructure to cooperate with a guide structure of a complementaryconnector to ease electrical coupling of the connector with thecomplementary connector.
 17. A battery case in accordance with claim 16in which said mount is supported in an end wall of said housing for freemovement in directions generally parallel to said end wall.
 18. Abattery case in accordance with claim 16 in which said housing includesa peripheral groove for movably receiving outer edges of said mount. 19.A battery case in accordance with claim 17 in which said mount is freelymovable in two dimensions within predetermined limits within saidgroove.
 20. A battery case in accordance with claim 16 in which saidguide structure of said connector includes at least one aperture adaptedto receive a guide pin.
 21. A battery case in accordance with claim 16in which said housing includes a pair of case members assembled togetherto define a generally rectangular housing.
 22. A battery case inaccordance with claim 20 in which said case members are joined along aseam, wherein longitudinal portions of said seam are generally locatedin opposite corners of the housing.
 23. A battery case comprising a pairof case members each having a pair of sidewalls joined to have agenerally V-shaped configuration, said case member being joined togetheralong a seam to form a generally rectangular housing for at least onebattery, wherein longitudinal portions of said seam are generallylocated in opposite corners of the housing.
 24. A battery case inaccordance with claim 23 in which said case members are identical toeach other.